Simple ways to reduce crimp failure or cost issues.

Simple ways to reduce crimp failure or cost issues.

The quality of a single termination can affect the operation of an entire electronic product, and that can cost companies thousands in Returns and other issues.

Fero - Crimping ToolsAt Fero, we understand manufacturing and assembly. Attention to detail is vital in ensuring smooth running of operations and products. We work through supply chain and engineering issues with clients using ‘fit for purpose’ principles, thereby minimising longer term issues in the solutions we provide.

Follow these simple tips to enhance your manufacturing design:

  1. Select the correct crimp and match it accurately to the wire size you are using.
    It seems obvious doesn’t it, but you would be surprised how often it happens. Always ensure you have the right type of crimp for the job and that it fits the wire correctly.
  2. Consider carefully the make and type of terminal you are specifying as many are only available in high MOQ’s and with long lead times. They may originally be available in small quantities to get you to the proto type stage but once in production we face the real issues. Fero is very happy to offer advice on whether you are considering common types of terminals that will not cause you problems later on. As we all are aware it is very hard to change terminals and connectors later that may need to be backwards compatible with your machinery or product.
  3. Crimping methods must be considered. We often face the difficulties in getting machinery to crimp unusual terminals and the costs associated start to become very relevant if we are not able to fully automate cutting of wires and automatic crimping. Once again Fero can offer advice on whether we can fully automate and utilize not only the lower costs but can ensure repeatability and quality of terminations using sophisticated “crimp force analysis” machinery in the crimping process.
  4. Pre-insulated terminals versus standard QC type (series 250) 6.3 tab or whatever you are used to calling the range of terminals. Pre-insulated terminals are great for auto electricians and low voltage systems, BUT they do not really compare to the quality of crimps associated with rollover type crimp terminals consistently crimped by purpose built applicators with full capability studies done to ensure full conductor compaction. Post fit insulators can then look after the insulation and you can ensure you have crimping that can handle medium voltage 110~240v and higher current without arcing. Air presses or hand tools through either PVC of Nylon hide a multitude of sins. We can also only fully automate the superior types of terminals so costs to you are lower.
  5. Having said that we have invested in more pre-insulated terminals and machinery as the customer is the ultimate decision maker.
  6. Carefully design form and fit for purpose. Don’t be tempted to rush it – time spent here is worth it. Remember the old saying measure twice, cut once? It’s as true in electrical engineering and hi tech manufacture!
  7. Determine the optimal temperature rating for your product and design around this to ensure working efficiency and a quality product.
  8. Match the physical properties of the crimp to the environment it will be used. Sourcing the right product and understanding how and where it will be used are a vital part of what we do to ensure a quality long term solution to our client’s needs.

Fero - crimped wire imageFero has provided electrical manufacturing solutions to the hi tech industry since 1987. Our team of engineers work tirelessly to design the right solutions and then our production teams assemble them quickly and carefully. It’s a simple process that has stood the test of time and maintained long term customer retention.

We deliver the following important services for our clients

  • Product design and specification with formalised worksheets
  • Process control – QA, capability and maintenance of high standards of production
  • Matching process to run size
  • Automated processes to reduce error and speed up production
  • Testing and sampling – in-house engineer to develop samples and test for standards and tolerances e.g. pull off testing.

To see more of work and understand how we work with our customers, click here to visit our website.

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